CHAPTER 7 FBISE

ELECTROCHEMISTRY
CORROSION AND ITS PREVENTION
CORROSION
Definition
“Corrosion is the process in which a metal reacts with oxygen and moisture in the atmosphere.”
It is a natural process that converts refined metals to the more stable metal oxides.
RUSTING OF IRON
Most familiar example of corrosion is the formation of rust on iron.
Conditions for rusting
Oxygen and water are necessary for iron to rust.
CHEMISTRY OF THE PROCESS
Reaction at anode: A region of metal surface that has relatively less moisture, acts as anode.
2Fe(s) 2Fe+2
(aq) + 4e
−

Reaction at cathode: Another region on the surface of metal that has relatively more moisture acts as
cathode. The electrons released in the oxidation process reduce atmospheric oxygen to hydroxyl ions.
−
O2(g) + 2H2 O(l) + 4e− 4OH(aq)
Rust formation
The Fe+2 ions formed at the anodic regions flow to the cathodic regions through the moisture on the surface.
Here Fe+2 ions further react with oxygen to form rust, Fe2O3.xH2O.

CORROSION OF ALUMINIUM
Corrosion is not limited to iron. Aluminium is extensively used in the construction of aircraft, ships, cars,
cooking utensil, window frames, soda canes etc. Aluminum has much higher tendency to oxidize than iron.
We might expect to see aircraft, ships, cars, cooking utensils, soda cans transformed into piles of corroded
aluminum. However, this does not occur.
Difference between oxide layer of Aluminium and oxide layer of iron
Aluminium corrodes but it does not rust. This is because a tough layer of insoluble aluminium oxide (Al2O3)
forms on its surface when metal is exposed to air. This layer firmly adheres to the metal and serves to protect
the underlying aluminum layers from further corrosion.
On the other hand, the insoluble layer of rust, Fe2O3.xH2O that forms on the surface of iron is too porous to
protect the underlying metal. This layer flakes away and exposes metal for further corrosion.

PREVENTION OF CORROSION
Prevention of corrosion is an important way of conserving our natural resources. Following methods have
been devised to protect metals from corrosion:

1. COATING WITH PAINT

Corrosion can be prevented by painting the metal, so that it does not come in contact with oxygen and
moisture and other harmful agents. Paint is cheap and easily applied. Paint is used to protect many everyday
steel objects such as cars, trucks, trains, bikes, bridges etc. Paint also provides visual appeal.

2. ALLOYING
The tendency of iron to oxidize can be greatly reduced by alloying it with other metals. For example,
stainless steel is an alloy of iron chromium and nickel. It is protected from corrosion by an outer layer of Cr2O3.
3. METALLIC COATING (Coating with a thin layer of another metal)
Metals that readily corrode can be protected by coating with a thin layer of another metal that resists
corrosion. This can be done by:
(a) Tinning
(b) Galvanizing
(c) Electroplating

(a) Tinning (Tin Coating)

In the process of tin plating, clean iron sheet is dipped in a bath of molten tin. It is then passed through
hot pair of rollers. Tin protects iron effectively, since, it is very stable.

(b) Galvanizing (Coating with Zinc)

The process of galvanizing consists of dipping a clean iron sheet in a hot zinc chloride bath and heating.
After this sheet is rolled into zinc bath and cooled.

(c) Electroplating
In electroplating an electrolytic process is used to deposit one metal on another metal.

4. CATHODIC PROTECTION
Cathodic protection is the process in which the metal that is to be protected from corrosion is made cathode
and is connected to metals such as magnesium or aluminium. These metals are more active than iron, so they
act as anode and iron as cathode. The more active metals themselves oxidize and save iron from corrosion.
Cathodic protection is employed to prevent iron and steel structures such as pipes, tanks, oil rigs etc. in the
moist underground and marine environment.

Cathodic protection